Reinforced metal alloy for enhanced armor protection and methods

ABSTRACT

An armor plate is provided having a lamination of an embedded reinforcement basalt fiber mesh within a laminated cast metal alloy; and at least two layers of an aramid fiber. A process to make the armor plate can include suspending a basalt weave within a mold; heating aluminum 6061 or 7075 alloy to a molten state; pouring the molten aluminum into the mold; cooling the resultant matrixed aluminum to ambient temperature; and laminating at least two layers of ballistic fiber to the matrixed aluminum.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a Non-provisional application of U.S. ApplicationNo. 62/351,735, filed on Jun. 17, 2016, the disclosure of which isincorporated herein by reference in its entirety.

FIELD

This application relates generally to body and vehicular armor,specifically to a method of enhancing base metal alloy for improvedenergy absorption, strength-to-weight ratio and ballistic resistanceperformance. Designs and methods are provided for an enhanced base metalfor hard armor panel assembly.

BACKGROUND

With the ever changing military and law enforcement conflicts andadvanced ballistic technologies, evolving needs for improved armorprotection for both personnel and vehicle systems have increased.Military and security personnel demand improved performance andreductions in equipment weight. The armor industry has struggled todevelop a system that is reliable and meets these critical, life-savingexpectations.

Armor designed to protect against projectile penetration can be made outof a variety of materials. Historically, metal-based armor was used formost armor applications. Current typical ballistic resistant platetechnology can incorporate a ceramic based plate adhered to a substrate.The plates, known as SAPI (small arms protective inserts) or ESAPI(enhanced small arms protective insert) can be placed within a fabriccarrier vest system for personal protection at the front, back and sidesof a wearer's torso. (See generally,https://en.wikipedia.org/wiki/Small_Arms_Protective_Insert) For example,the United States Army has issued requests and solicitations forimproved ballistic plate technology to be known as XSAPI which willprovide greater coverage and reduced weight. Accordingly, there is adesire and need in the art to address these requests and solicitationsin the next generation of SAPI protection.

SUMMARY

The present embodiments include methods to produce a reinforcementlamination for a metal alloy to be used for ballistic resistant armorapplications such as personnel or vehicular armor plates.

According to one approach, an armor plate can be a lamination of anembedded reinforcement basalt fiber mesh within a laminated cast metalalloy; and at least two layers of an aramid fiber. The armor plate mayalso have at least at least one titanium layer. In one embodiment thearmor plate may also have a ballistic fiber wrap. The armor plate mayalso have a metal alloy that is aluminum 6061 or 7075. The armor platemay also have an optional 10 mil blast mitigation and protective coat.The armor plate may also have a label on a side of the plate configuredto be the strike face surface, the label identifying the strike face anda standardized classification and any other desired indicia. The armorplate may also have at least one titanium layer that is 1/16″ thick. Thebasalt fiber mesh opening can be between ⅛″ and ⅜″ square. The laminatedcast metal alloy can be ⅜″ thick.

According to another approach, a method of making an armor plate caninclude the steps of suspending a basalt weave within a mold; heatingaluminum 6061 or 7075 alloy to a molten state; pouring the moltenaluminum into the mold; cooling the resultant matrixed aluminum toambient temperature; and laminating at least two layers of ballisticfiber to the matrixed aluminum. In some embodiments the aluminum can beheated to about 1,400 degrees Fahrenheit. In some embodiments, thelaminate may further have the step of vacuum infusing an elastic resinto seals all the lamination seams. The step of suspending a basalt weavewithin a mold can use caplets or other types of spacers. A step ofspraying the armor plate with a blast mitigation and protective coat mayalso be included.

This Summary is intended to provide a brief overview of some of thesubject matter described in this document. Accordingly, it will beappreciated that the above-described features are merely examples andshould not be construed to narrow the scope or spirit of the subjectmatter described herein in any way. Other features, aspects, andadvantages of the subject matter described herein will become apparentfrom the following Detailed Description, Figures, and Claims.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing features, as well as other features, will become apparentwith reference to the description and figures below, in which likenumerals represent like elements, and in which:

FIG. 1 illustrates an exemplary flow chart depicting a general assemblyprocess of the present invention in a typical embodiment.

FIG. 2 illustrates a plan view of a typical prior art armor plate knownin the industry as a small arms protective insert (SAPI) plate.

FIG. 3 illustrates an exemplary cross-sectional view of the enhancedbase metal within the mold of an exemplary embodiment according to oneapproach.

FIG. 4 illustrates an expansible energy absorbing layer for use inconjunction with a hard armor construction such as that of FIG. 3 of anexemplary embodiment according to one approach.

FIG. 5 illustrates a perspective view of an exemplary mold embodimentaccording to one approach with the basalt mesh.

FIG. 6 illustrates a perspective view of the exemplary mold of FIG. 5with the basalt mesh disposed therein for casting of molten aluminum.

FIG. 7 illustrates a perspective view an exploded view of the moldedmatrix aluminum of FIG. 6 with a titanium plate.

FIG. 8 illustrates an exploded partial cross section of an assembledplate of an exemplary embodiment according to one approach.

FIG. 9 illustrates a partial cross section of an exemplary embodimentaccording to the embodiment of FIG. 8 with an application of a blastmitigation and protective spray on coating.

FIG. 10 illustrates a plan view of an exemplary armor plate embodimentaccording to one approach.

FIG. 11 illustrates a cross sectional view of the armor plate of FIG. 10taken along section lines XI-XI.

FIG. 12 illustrates a plan view of an exemplary armor plate embodimentaccording to one approach.

FIG. 13 illustrates a cross sectional view of the armor plate of FIG. 12taken along section lines XIII-XIII.

FIG. 14 illustrates an exemplary process flow of assembly steps of anexemplary embodiment according to one approach.

FIGS. 15-18 illustrate and an exemplary embodiment of a molding deviceaccording to one approach.

While the features described herein may be susceptible to variousmodifications and alternative forms, specific embodiments thereof areshown by way of example in the drawings and are herein described indetail. It should be understood, however, that the drawings and detaileddescription thereto are not intended to be limiting to the particularform disclosed, but on the contrary, the intention is to cover allmodifications, equivalents and alternatives falling within the spiritand scope of the subject matter as defined by the appended claims.

DETAILED DESCRIPTION

With the ever changing military and law enforcement theatres, evolvingneeds for improved armor protection for both personnel and vehiclesystems have increased to meet lighter weight and higher performanceexpectations. The exemplary metal alloys and methods described hereinand depicted in the figures are configured to meet these increasedexpectations.

The present embodiments include methods to produce a reinforcementlamination for a metal alloy to be used for ballistic resistant armorapplications such as personnel or vehicular armor plates. In oneembodiment the base metal is configured with mesh reinforcement (e.g.,carbon fiber or basalt) within the layer (including a cast layer) toprovide enhanced strength and energy absorption characteristics.

According to one approach, through innovative nanostructured alloyassembly development, some embodiments can enhance the materialperformance characteristics of the base metal for use in defense armorapplications. Although the present embodiments and assembly principlesare described for armor applications, it is noted that these embodimentsand methods may also be applied to industrial, structural applications,and the like where improved strength to weight ratios are of criticalimportance.

One aspect of the invention includes a process for embedding areinforcement fiber mesh such as, but not limited to, carbon fiber orbasalt fiber within a cast metal alloy, such as but not limited to,aluminum 6061 or 7075 alloy. Other base metals may be used for enhancedperformance characteristics. Within this embodiment, the mesh may besuspended within the mold prior to casting and held in place duringcasting with metal standoffs or nibs or caplets or other types ofspacers to help to maintain the position of the reinforcement to ensurecoverage at both sides of the reinforcing material. Following thecasting process, the plate is allowed to cool and removed from the mold.In one embodiment, the plates can be prepared with a finish edgetreatment such as weld and then wrapped with an aramid fiber orballistic composites wrap such as a ballistic wrap sold under thetradename SPECTRA/SPECTRA GOLD (by Honeywell of Colonial Heights, Va.),or DYNEEMA (by Royal DSM of the Netherlands). In a preferred embodiment,the finish edge can be infused with a resin. Depending on the targetedthreat level, a layered backup system may be incorporated in someembodiments having of a series of ballistic fabric materials such as aballistic foam or an aramid fiber sold under the tradename KEVLAR (byDuPont) or any various types of ultra-high-molecular-weight polyethylene(UHMWP) polymers.

The present embodiments provide several advantages over the known art.One key advantage is the comparative lightweight nature of the productwith enhanced strength-to-weight performance of the assembly. Thisfactor will allow military, police and security personnel to wear theprotective gear for longer periods of time without additional strain ofcarrying added weight. Another advantage is its ability to potentiallywithstand multiple ballistic rounds. This innovation will allowsoldiers, police or other security forces to remain engaged in conflictwithout the immediate need to take cover, retreat, or otherwisedisengage in order to replace the damaged gear. And yet anotheradvantage is its ability to absorb ballistic rounds received at an angle(its “obliquity”) (e.g., 0 to about 20 degrees from perpendicular)rather than ricocheting the bullet to potentially cause additional harmonce deflected. For example, ceramic based armor plates can frequentlydeflect bullets into the wearer's arm, torso or neck, or into a fellowsoldier in an adjacent position. Capturing a bullet round enhances thesafety of those seeking protection. The composite nature of thereinforced metal further improves flexibility, strength and resistanceto deformity and failure.

The present embodiments involve matrixed aluminum configured, forexample, to be utilized in conjunction with product applications to meetvarious military and law enforcement expectations for lighter weight andhighly capable body armor. It is known that matrixed aluminum, byitself, cannot meet the performance criteria for the higher threat levelapplications. However, the present embodiments' added layers whichsynergistically interact together to reinforce the design, define andrefine the layup applications to result in a final process and product.Materials needed according to one approach can include a matrixedaluminum plate—6″×6″×⅜″ (″=inches), SPECTRA Cloth, KEVLAR, a blastmitigation and protective spray on (or dipped) coating such as a RHINOCOATING (by Rhino Linings Industrial), and optionally labels to indicatestrike face and ratings.

According to another approach, a wearable-enhanced-protective-system(WEPS) can be a laminated series of layers functioning homogeneously tomitigate Level 3A ballistic threats. These can include 9 mm FMJ, .357SIG/FMJ and 44 MAG/SJHP as well as the 5.52 FMJ Rifle Round shot at 49feet from an AR15 Assault Rifle. This gives the System a Level 3A+Rating based on National Institute of Justice (NIJ) Criteria. The WEPSsystem of the current embodiments can be a series of laminations andcoatings. According to one approach, the system can have a titaniumstrike face that is the initial surface contact a round would encounterto significantly degrade the level 3A rounds so that the subsequentlayers can further degrade and capture the round with limited backfacedeformation and no penetration.

FIG. 1 illustrates a flow chart depicting a general assembly process 100of the present invention in a typical embodiment. As shown, at step 102retention devices can be placed within the mold to maintain the positionof reinforcement during casting. Next at step 104, a fiber insert can beinserted within the mold. Next a step 106, molten metal can be castwithin the mold at about, for example, 1,400 degrees Fahrenheit. In anyevent the metal to be cast in the mold needs to be to a temperature thatit is flowable into the mold, and through and around, the basalt mesh.Next, at step 108 the mold plates are cooled to ambient temperature andcan be removed followed by step 110 to assemble the molded plate into aballistic system.

FIG. 2 illustrates an exemplary plan view of a typical prior art armorplate known in the industry as a small arms protective insert (SAPI)plate for mounting at the front into an armor vest carrier system. Forconvenience the enhanced base metal layers shown are in the shape of aSAPI (e.g., 6″×6″×⅜″ or 10″×12″×⅜′), however the enhanced base metallayers may take any shape needed for a particular armor panel.

FIG. 3 illustrates an exemplary cross-sectional view of the enhancedbase metal within a mold. In this embodiment, basalt or carbon fibermesh has been suspended within a cast metal. FIG. 3 shows a moldassembly generally indicated at 300, which includes a steel or othermetal mold 314; a metal alloy (such as aluminum 6061) 310; carbon fibermesh, basalt fiber mesh, or other reinforcing mesh 312; and moldapparatus to maintain position of reinforcement during casting 318.

FIG. 4 illustrates an exemplary embodiment of an expansible energyabsorbing layer 400 for use in conjunction with a hard armorconstruction such as that of FIG. 3. The layer 410 may be constructed ofvarious sheet metals including titanium (including Grade II or grade Vtitanium), stainless steel, cold-rolled steel or the like.Alternatively, the layer 410 may be constructed of various lighterweight fabric composite materials. Layer 420 can be a ballistic fiberwrap.

According to another approach shown in FIGS. 5-7, a layered series ofmatrixed aluminum (MAL) is provided. As shown in FIG. 5, anergonomically shaped (i.e., configured to contour the shape of the userwhere it is positioned or to give the plate a curvature for a morecomfortable application with the contours of a user's body) mold 514 canreceive, for example, three layers of a mesh material, such as a basaltmesh 510 at about 1/16″ to ¾″ and preferably about ⅛″ in thickness. Thebasalt mesh 510 can be a weave or separated into layers. As shown inFIG. 5, the basalt mesh 510 can optionally be held in place with caplets512 positioned as sacrificial components to hold the basalt mesh 510 inplace during the pouring. In one embodiment shown in FIG. 6, thematrixed aluminum 520 can be a 6061 series grade aluminum, which ismelted for this alloy to about 1,400 degrees F. The basalt mesh (orthree separate mesh layers) 510 can be positioned in the center (or nearthe center) of mold 516. The molten aluminum 520 can be poured fromvessel 518 into mold 514 and allowed to cool to ambient temperaturebefore extraction. The extraction can produce, for example, a 12″×12″×⅜″plate 522 (FIG. 7) with the integrated basalt mesh that can then beprocessed to the design dimensions for the product and to receiveadditional laminations to achieve the desired specifications. Forillustrative purposes, plate 522 can receive a titanium plate 524.

As shown in FIGS. 8 and 9, the matrixed aluminum plate 522 can then beintegrated with an alternating layered/stacked system of KEVLAR andSPECTRA GOLD with titanium sheet of about 1/32″ to ¾″ in thickness ofKEVLAR (preferably about 1/16″) in the middle that is laminated tocreate a layered thickness of “⅛ to 1”, preferably about ⅜″. Thesestacked layers can then be wrapped with, for example, 3 layers of KEVLARand then vacuum infused with an elastic resin that seals all seams tocreate the homogeneous plate 600. These aramid fiber and UHMW productswork together to capture the ballistic rounds and disperse the energytransferred to the wearer. As shown in FIG. 8 in exploded view to showdetail of an exemplary lamination (shown as a laminate in FIG. 9) 600,having the three KEVLAR wraps 536, 538 and 540 around the entire plate,a titanium plate 524, the matrixed aluminum plate 522 with its threelayers of basalt fibers 510; a first blast mitigation fiber SPECTRA GOLDsheet 534, a second Kevlar plate 532, a second titanium sheet 530, asecond blast mitigation fiber SPECTRA GOLD sheet 528, and an additionalKEVLAR sheet 526. The sheets can the about 1/32″ to ¼″, and preferablyabout 1/16″ in thickness depending to the desired certification ratingand blast absorption desired for the plate.

Finally, as shown in FIG. 9, a completed plate 600 can be dipped/sprayed(612) by nozzle 614 with a 5-50 mil, preferably a 10 mil, thickLINEX/RHINO coating 610 that ensure the mitigation of any spalling andprovides the aesthetic features to the final product. Products can thenbe inspected for quality and a decal is adhered to the plate identifyingthe strike face and the threat level certifications and warnings.

FIGS. 10 and 12 show other exemplary plate configurations with a crosssection of each respectively in FIGS. 11 and 13 showing the laminationarrangement. The plate of FIG. 10 can, for illustrative purposes only,can be 11.5″ tall 684, angled corners of about 4″ 686 and 2″ 690, about10.5″ wide 688, and a ½″ radius 692. The plate can have a label 680 onthe strike surface having indicia indicating as much plus any otherinformation about certification level, graphics, tradenames, and thelike. Plate 600 i can also be curved or contoured 694 in a variety ofmanners as desired. As shown in FIG. 11, plate 600 i can have threelayers of Kevlar complete wrap 536, 538, 540 sealed with resin infusionfor a homogenous finish and a LINEX coating complete. Within the Kevlarwraps from the strike face side downward the plate can include a ⅛″ Gr5titanium plate 524, a ⅜″ ballistic metal foam layer 698, a 1/16″ Gr5titanium sheet 530 and a ⅜″ thick lamination of alternating layers ofSPECTRA/KEVLAR 526, 534. In a preferred embodiment 14 alternating layersare present. Total thickness 696 of plate 600 i is about ¾″.

The plate 600″ of FIG. 12 can, for illustrative purposes only, can beabout 6″ by 6″ height/width, and a ½″ radius same as plate 600 i. Theplate can have a label 680 i on the strike surface having indiciaindicating as much plus any other information about certification level,graphics, tradenames, and the like. Plate 600 ii can also be curved orcontoured in a variety of manners as desired. As shown in FIG. 13, plate600 ii can have three layers of Kevlar complete wrap 536, 538, 540sealed with resin infusion for a homogenous finish and a LINEX coatingcomplete. Within the Kevlar wraps from the strike face side downward theplate can include a ⅛″ Gr5 titanium plate 524, a ⅜″ matrixed aluminumplate 522, a 1/16″ Gr5 titanium sheet 530 and a ⅜″ thick lamination ofalternating layers of SPECTRA/KEVLAR 526, 534. In a preferred embodiment14 alternating layers are present. Total thickness of plate 600 ii isalso about ¾″.

FIG. 14 illustrate a process flow of a progression of an armor plateassembly steps of an exemplary embodiment 600 iii. In this embodiment,several layers, for example in FIG. 14 A alternating layers of KEVLAR525 and SPECTRA 534 sheets are stacked on a matrixed aluminum plate 522for form laminate 142, which is about 5″ by 5″ square. The number oflayers can be up to 14 or more or less depending on the overallthickness of the final plate 600 iii not exceeding a predeterminedthickness. For example, some plates may be required to be no more than¾″ or 1″ in thickness. Accordingly, alternating layers of SPECTRA/KEVLAR526, 534 can be added until that overall thickness (e.g., 1″) isachieved. Laminate 142 is then wrapped by a spectra sheet 534 i having awidth 156 of about 16.75″, four tabs 160 about length 152 of about 5″, abase dimension 154 of about 0.375″, a base width 150 of about 6″ and atapered end width 148 of about 5″. The SPECTRA SHIELD 534 i is thenenveloped as shown to form plate 600 iii.

Another exemplary assembly approach to produce the matrixed aluminumplate 522 is shown in FIGS. 15-18. In this process a base frame 311 ofdevice 301 holds mounted angled aluminum ‘C’ frame 315 attached to areciprocal frame 313 by a hinge (such as a piano hinge) 317 that can beclamped together with butterfly clips 322 to hold the angled aluminumpieces and/or the mold pieces (319 and 320) in place. As shown though,mold halves 319 and 320 can be retained in place during the pouring ofthe molten aluminum step by other means known in the art. Mold piece 319is a tray having an enclosed bottom and a reciprocal mold piece 320 ofmatching dimensions also having ports 360 to pour in the molten aluminumand vent 362 to allow air to escape. Many types of mold configurationsare possible including vent and pour openings. This embodiment is shownto assist in the understanding of device 301. The inner dimension of themold pieces 319 and 320 match the outer dimensions of a desired matrixedaluminum plate 522. The depth of tray 319 matches the position of thebasalt weave layers within the final plate 522. As shown in FIG. 16, thebasalt weave 510 is stretched across the frame pieces and clamped inplace. At this point, the molten cast metal can be poured into the moldpieces to the desired thickness. FIG. 18 shows a cross sectional view ofthe frame with the basalt weave 510 in place. As shown the angledaluminum and the mold frame are clamped in place. It is noted that thebasalt mesh/weave 510 can have a variety of sized pores/openings/spacingbetween the weave strands, such as shown at 364 in FIG. 17. Preferablythe opening 364 is between ⅛″ to ⅜″ square. The weave opening though isconfigured to allow the molten aluminum to flow through the basalt mesh510 in the casting process, but provide the strength needed for thedesired strength needed for the configured application.

According to another approach, the present embodiments can utilize aproprietary sequenced manufacturing distribution process of materialsand layers under controlled environmental conditions to ensure aconsistent, reliable, and reproducible end product. Sheet metal rollingtechniques can be employed and tested, including hot/cold rolling,stamping, perforating, and/or casting. Composite matrix materials can beevaluated to determine applicability for bonding, strength, andproduction benefits. Advanced fabrication techniques such as computernumerical control (CNC) milling, laser/water jet, and/or rapidprototyping can be utilized.

Performance criteria of a resultant composite base metal can beenhanced, and verified through rigorous testing and certificationprocesses. Standard metrics such as, shear, tensile strength, and heatdissipation, can be measured and compared to create products thatoutperform current National Institute of Justice (NIJ) target threatlevel specifications. Other industry applications can be reviewed todetermine potential candidates for future modification and enhancement.The targeted base metal material has several potential industryapplications, including personal body armor and vehicle armorapplications, structural and building component applications, marineapplications, and electrical and electronic conductive applications.Following the initial proof-of-concept phase, prototype results can beused to determine suitability for various applications. Such as shown inthe following table:

TABLE THICKNESS THICKNESS SYSTEM ASSEMBLY - LAYER (IN) (IN) DIMS WT(LBS) DIMS 1 System Assembly #1 - Threat Leve IIIA (plus) WRAP 1 SpectraShield SR-1226 - Inner Wrap 0.0625 1/16  12″ × 12″ 10.5″ × 11.5″Matrixed Aluminum 0.3750 ⅜  12″ × 12″ 10.5″ × 11.5″ WRAP 2 SpectraShield SR-1226 - Inner Wrap 0.0625 1/16  12″ × 12″ 10.5″ × 11.5″ Kevlarsheets (8) 1 0.0090 8/889 12″ × 12″ 0.0972 10.5″ × 11.5″ 7 0.0630 8/12712″ × 12″ 0.6804 10.5″ × 11.5″ WRAP 3 Kevlar sheets (3) - Outer Wrap0.0625 1/16  12″ × 12″ 10.5″ × 11.5″ Rhino Spray Coating 0.0625 1/16 12″ × 12″ 10.5″ × 11.5″ TOTALS: 0.6970 0.6970 0.0000 0.7776 0.6521 2System Assembly #2 - Threat Leve IIIA (plus) WRAP 1 Spectra ShieldSR-1226 - Inner Wrap 0.0625 1/16  12″ × 12″ Titanium sheet - Grade 50.0280 7/250 12″ × 12″ 0.6572 Matrixed Aluminum 0.3750 ⅜  12″ × 12″ WRAP2 Spectra Shield SR-1226 - Inner Wrap 0.0625 1/16  12″ × 12″ Kevlarsheets (8) 1 0.0090 8/889 12″ × 12″ 0.0972 7 0.0630 8/127 12″ × 12″0.6804 WRAP 3 Kevlar sheets (3) - Outer Wrap 0.0625 1/16  12″ × 12″Rhino Spray Coating 0.0625 1/16  12″ × 12″ TOTALS: 0.7250 0.7250 0.00001.4348 1.2031 3 System Assembly #3 - Threat Level IIIA (plus) WRAP 1Spectra Shield SR-1226 - Inner Wrap 0.0625 1/16  12″ × 12″ StainlessSteel - 18 gauge - Type 304 or 316 0.0480 6/125 12″ × 12″ 2.0160Matrixed Aluminum 0.3750 ⅜  12″ × 12″ 5.238 WRAP 2 Spectra ShieldSR-1226 - Inner Wrap 0.0625 1/16  12″ × 12″ Kevlar sheets (8) 1 0.00908/889 12″ × 12″ 0.0972 7 0.0630 8/127 12″ × 12″ 0.6804 WRAP 3 Kevlarsheets (3) - Outer Wrap 0.0625 1/16  12″ × 12″ Rhino Spray Coating0.0625 1/16  12″ × 12″ TOTALS: 0.7450 0.74500 0.00000 8.03160 4 SystemAssembly #4 - Threat Level IIIA (plus) WRAP 1 Spectra Shield SR-1226 -Inner Wrap 0.0625 1/16  12″ × 12″ Stainless Steel - 18 gauge - Type 304or 316 0.0480 6/125 12″ × 12″ 2.0160 Matrixed Aluminum 0.3750 ⅜  12″ ×12″ WRAP 2 Spectra Shield SR-1226 - Inner Wrap 0.0625 1/16  12″ × 12″Kevlar sheets (8) 1 0.0090 8/889 12″ × 12″ 0.0972 7 0.0630 8/127 12″ ×12″ 0.6804 WRAP 3 Kevlar sheets (3) - Outer Wrap 0.0625 1/16  12″ × 12″Rhino Spray Coating 0.0625 1/16  12″ × 12″ TOTALS: 0.7450 0.745000.00000 2.79360

Aluminum treatments can also be considered for the present embodiments.Treatments of ferrous and nonferrous castings can receive differenttypes of heat treatment. Aluminum castings can be heat treated usingdifferent combinations of operations, called tempers. Heat treatment ofaluminum castings can result in homogenization, stress relief, andimproved stability, machinability and mechanical properties.

The thermal processing can involve three basic processes—solution,quenching and aging. During solution, elements that will later cause agehardening are dissolved, undissolved constituents become spheroids, andthe microstructure of the casting is homogenized. Homogenizationdistributes the alloying and impurity elements of a casting throughoutits matrix, so the casting's properties will be more uniform.

Rapid cooling, or quenching cycles, retain the dissolved elements in thesolution. Rapid quenching increases the response to age hardening, butit also creates residual stresses and distortion. Dissolved elementsthat are trapped in the solution during quenching eventually precipitateslowly at room temperature. After a time at room temperature, somealloys will harden appreciably. Aging can be accelerated by heatingcastings to intermediate temperatures in a process called artificialaging. Increased time at age temperature or aging at a greatertemperature further evolves the precipitate structure, and hardnessincreases to a peak hardness condition. After the peak is hit, furtheraging, or overaging, reduces the hardness.

Aging also affects ductility. During overaging, a loss of hardeningmechanisms permits extensive deformation to occur before fracture andductility increases. Annealing, which is extreme overaging, maximizesductility. Although each alloy and temper can have a recommendedsolution, quench and age times, these cycles are often customized tomeet specific requirements for strength and ductility.

In another approach, additional titanium to the strike face to helpdegrade the rounds on the strike face gives the layered wraps morestopping opportunity. In one embodiment, a test fired AR15—5.56 FMJround resulted with no penetration and limited BFD. This was with 0001which did have a 12 gauge Titanium Layer on the strike-face as well. Oneembodiment utilized just a Layup and Matrixed Aluminum assembly with the.125 Titanium as the Strikeface and defeated the AR15/5.56 FMJ Round aswell.

An AK47/7.62 round could be defeated with an embodiment having a 1.25Strikeface/Matrixed Aluminum/.125 Titanium/Spectra-Kevlar Layup. Thiscould work for Level 3. However, significantly increased weight and costwould result. Optional embodiments could incorporate a Ballistic Foam togo before the matrixed aluminum.

Any references to the advantages, benefits, unexpected results, oroperability of the present invention are not intended as an affirmationthat the invention has been previously reduced to practice or that anytesting has been performed. Likewise, unless stated otherwise, use ofverbs in the past tense is not intended to indicate or imply that theinvention has been previously reduced to practice or that any testinghas been performed.

Although specific terms are employed herein, they are used in a genericand descriptive sense of only and not for purposes of limitation. Unlessotherwise expressly defined herein, such terms are intended to be giventheir broad ordinary and customary meaning not inconsistent with thatapplicable in the relevant industry and without restriction to anyspecific embodiment hereinafter described. As used herein, the article“a” is intended to include one or more items. Where only one item isintended, the term “one” or “single” or similar language is used. Whenused herein to join a list of the items, but does not exclude aplurality of items of the list.

While the embodiments have been described in conjunction with specificembodiments, it is evident that many alternatives, modifications andvariations will be apparent to those skilled in the art in light of theforegoing description. Accordingly, the present embodiments attempt toembrace all such alternatives, modifications and variations that fallwithin the spirit and scope of the appended claims. Throughout thisspecification and the drawings and figures associated with thisspecification, numerical labels of previously shown or discussedfeatures may be reused in another drawing figure to indicate similarfeatures.

I claim:
 1. An armor plate, comprising a lamination of: an embeddedbasalt fiber mesh within a laminated cast metal alloy, at least twolayers of an aramid fiber, a ballistic fiber wrap, and a 10 mil blastmitigation and protective coat.
 2. The armor plate of claim 1, furthercomprising at least one titanium layer.
 3. The armor plate of claim 1,wherein the metal alloy is aluminum 6061 or
 7075. 4. The armor plate ofclaim 1, further comprising a label on a side of the plate configured tobe a strike face surface, the label identifying a strike face and astandardized classification.
 5. The armor plate of claim 2, wherein atleast one of the at least one titanium layer is 1/16″ thick.
 6. Thearmor plate of claim 1, wherein the basalt fiber mesh has openings inthe range of ⅛″ and ⅜″ square.
 7. The armor plate of claim 1, whereinthe laminated cast metal alloy is ⅜″ thick.
 8. A method of making anarmor plate comprising the steps of: suspending a basalt weave within amold; heating an aluminum 6061 or 7075 alloy to a molten state; pouringthe molten aluminum 6061 or 7075 alloy into the mold; cooling theresultant matrixed aluminum to ambient temperature; and laminating atleast two layers of ballistic fiber to the matrixed aluminum to form alaminate.
 9. The method of claim 8, wherein the aluminum 6061 or 7075alloy is heated to about 1,400 degrees Fahrenheit.
 10. The method ofclaim 8, further comprising the step of vacuum infusing an elastic resinto seal all lamination seams.
 11. The method of claim 8, wherein thestep of suspending a basalt weave within a mold uses caplets.
 12. Themethod of claim 8, further comprising the step of spraying the armorplate with a combined blast mitigation and protective coat.